Steam boiler and setting



Jan. 3, 1928. 1,655,057-

C. G. HAWLEY STEAM BOILER AND SETTING FledSept. 12. 1921 5 Sheets-Sheet l Ilnventfar Jam.l 3, 1928.

STEAM BOTLER AND SETTING HAWLEY Filed Sept. 12. 41921 5 Sheets-Sheet 2 Q u melf.

Jan. 3, 1928. 1,655,057

C. G. HAWLEY STEAM BOILER AND SETTING Filed Sept. 12. 1921 3 Sheecs-Sheetl 3 All Patented Jan. 3, 1928.

i CHARLES GILBERT HA'WLEY,` 0F. CHICAGO, ILLINIS.

STEAM BOILER AND SETTING.

l Application filed September 12, 1921. Serial No. 500,107.

My invention relates to improvements in steam boilers, including the settings and furnaces therefor.

This application is ap continuation ofcertain of the subject matters disclosed and claimed in my former case S. N. 304807,1'iled June 14,1919, allowed March 18, 1921, and abandoned in favor of this application. The object of the invention is to provide a boiler of a new type, for heating and pow er purposes; .and which, compared with those now in use, shall `be of less weight, of smaller size, of lower cost,` and-less expensiveV to install and .to maintain ;-and especially, to provide a boiler which shall be safer and more durable than others ;-par ticularly under conditions of forced firing. A special object of the invention `is to provide a boiler that shall be'better adapted to a more rapid circulation ofthe boiler Water and the efcient utilization of the radiant heat of the tire, and therefore of greater capacity and efficiency. Further special objects are to provide a boiler of a unit form,

complete in itself, and tothe `end that either a single boiler' or a plurality thereof maybe used in a single setting or lire chamber, and to the further end that the novel boiler, in each `of several. standardsizes, may become a standard factory product adapted, for manutacture by yecononiical quantity production methods, and in sizes best suited to such processes of manufacture, and for transportation by rail or water.

1 attain these objects and other objects hereinafter set forth by novel arrangements of heating surfaces, `and by novel constructions throughout `theboiler and the boiler setting; `all as hereinafter described and particularly pointed out in the appended claims. l

'llhe invention `will be readily understood on reference to the accompanying drawings, wherein `l haveillustrated the invention in what l regard as its best forms, and in which; Fig.` 1 is a longitudinal vertical section of a steam boiler and setting-embodying my invention; 2 is a horizontal section on the line 2--2 of Fig. 1; Fig. 3 illustrates a modified form of my invention; Fig. 4. shows a further modification thereof; Fig. 5 is a vertical cr'osssection :on the lines 5-5 `of Figs. 1 and2; Fig. 6 is a `vertical cross section on the lines G-t of Figs. 1 and 2. shows two of my novel unit boilers in a single setting; Fig. 8 is a like View showing three ofthe units over a single grate;

Fig. 9 illustrates a modified form of theV Fig. 13 is a vertical section onthe line 13-V of Fig. 11;"Fig. 14 is a front end elevation of a unit which embodies top and bottom drums of still lalrOer dimensions and which has two of the water steaming and circulating walls; Fig. 15 is a vertical section on the line 15-of Fig. 111; and Fig. 16 is a horizontal section `of a water circulating wall, as viewed on any of the lines 16S-j of t-he several figures. s

l may build my unit boilers, assemblies thereof, andthe settings therefor, in many different sizes and shapes to suit various conditions, and it is to be understood that the structures herein shown and described are by way of illustration only, and are not to be regarded as the limits of the inven-` tion. Thus, all of the boiler units or unit boilers, shown in Figs. 1 to 10, are of a single size; this in order to clearly presentthe method which l follow in multiplying the number of separate boilers or units as required to gain the desired capacity andieiliciency from the :boiler as a whole. ln each case the dimensions of the grate may be regarded the criterion controlling the overall dimensions of the boiler, and the number of units employed has to do with the ultimate eiliciency of the boiler. Y

The bare boiler, or single unit, detailed in Figs.` 1, 2,5 and 6 `comprises a long top drum, A, for water and "steann-a short bottom (lli titl

drum, B, for water and mud,a thin, stay bolted water-wall, C, of generallytriangular shape,leading from the drum B into the bot-torn of the drum, y1-and a group of vertical water tubes,`or other return passage, D, joining the bottom of the drum A, and the top of the. drum B. In this form, the unit or boiler is ready for installation, and is fitted for actual use by adding the necessary safety valve, water gauge, feed water and blow-olf connections. When two or moreunits are used in'a single setting, the bottom drums are interconnected, as by couplings G (Figs. 7 and 8) to ensure a uniform Water level in the top drums, and the severa-l steam outlets, H, of the units are wall Cx, the drum head B", and the front half Ax of the top drum. The other section comprises the back half Ay ofthe top drum, the bottom drum By and the many watertubesDX, which join the drums. Each Section 'is `completed at the factory. On arrival at the place of installation the sections are telescoped (as indicated by dotted and full lines in Fig. ll) land they are then riveted together, as shown at points O in Fig. 1l. The joints are then caulked `or welded to make them steam tight. Thus the Work in the field is reduced to a minimum.

For the further study of the practical phases of the matter, `it-may be assumed that the exemplary boiler unit` shown in Fig. 1-8 is fourteen to eighteen feet long and little vover nine feet high; that `the two drums, A and B, and the water-wall, C, are made of sheets three-eighths of an inch thick; that the water space, (Fig. 5) in the water-wall is three to four inches wide; that the drums A and B are about twentyfour inches in diameter; and, that the tubes I), Aare of twelve gauge and two-anderhalf inch diameter. A unit of such dimensions weighs about five thousandpounds, and when used singly in a setting, such as shown in Figs. 5 and 6, is ofone hundred to one hundred and fifty horse power capacity,

withinthe range of ordinary rates of co1nbustion in the lire chamber.v

As a further example, the large `power unit of Figs. ll and 12 may have the folJ lowing dimensions.` Each section has a length of about ten feet, which adapts them foi shipment on ordinary railroad cars. The drums are of thirty two inch diameter. The water space within the wall C? may be from three to four inches wide. The capacity of such a unit ranges from one hundred andfifty to two hundred and fifty boiler `horse-power,according to the rate at which itis fired.

Desired increases of capacity may be .secured by placing twoor more of these units in a single setting and such multiplication of units may well be resorted. to for the purpose of providing a boiler of maximum efliciency. i

I now call attention to the varying shapes of the water circulating and steaming walls shown in Figs. 1, 3, 5, 9 and Il. VVhileof different shapes each thereof is of an in verted substantially triangular shape; inas much as each presents a neck shaped apex C to the bottom drum, and presents a wide base C" to the top drum. As well shown the area of the neck or intake connection CV in every case, is very much sinallei` than the outlet opening or slot C, within the base portion CW. The water which enters from `the bottom at high velocity, so to speak, takes on or expands to the shape of a fan within the thin water wall, and rapidly ascends therein due to much of "itbeing evaporated., but always moves at a much lower speed than at the intake C'. It is in the sense of this paragraph that I shall heren inafter employ the term substantially triangular water Wall. As a rule also, this implies that the true bottom or lower part C" of the water wall trends or slants upward from the intake, so that the spreading or fanning out of the water may take place without so great a cessation of upward movement as to admit of the deposition and accumulation of mud or loose scale in the forward part of the water wall. As a further precaution in this last respect I equip soine of these water walls with means Cz for blowing off any accumulations that may be found therein.

Each water wall is Amade preferably of one sheet of metal folded upon itself and with its meeting edges flanged together and` welded as shown in Fig. 16. The flat sides of the wall are then joined by properly spaced stay bolts S. TWhere the wall is of the drawings.

The water wall of Fig. 1 :is of a single triangular forni. This form is departed from in Fig. 9, with a View to increasing` the heating surface. But in this last regard I much prefer the structurally simpler shape shown in Figs. 3 and 11. There the wall is distinguished by a distinct blow-off neck CS; and beside,l has the advantage of a. bulging bottom, or beam, portion Ct which is of uniform diameter from neck Cv to neck C. In passing, it should be explained that these bulging bottom portions are distinctly advantageous because they ensure the free and uniform distribution of the strong currents of water that enter through the intake neck C", and furthermore, as they are self stayed` it becomes unnecessary to carry the stay bolting so low a-s to obstruct the flow of water orniud upward along the bot-tom of the water wall.

That modification shown in Figs. 14: and l5 seems to be self explanatory. Thereby, I succeed in doubling the water wall capacity, in proportion to thedruin and water tube portions of the unit. To do this, I employ a main top drum C2 (for the water tubes) and provide each water wall C3 with its own topdruin Ct. These are smaller, so that two thereof may enter and be attached to the front head C5 of the main are likewise applicable to Vany steam boiler' which comprises drums and Water tubes which occasionally must be cleaned. ln my boilers all of the internal surfaces are accessible through the man holes )rovided in the ends thereof. But l much prefer the addition of the parts AW. Vthey are small band holes, with covers, andare spaced at convenient distances in or upon the top of the boiler. Through these a man Working in an tu right position upon the top of the boiler may easily insert` and Work the usual cleaning' tools, as indicated by the flexible shaft, power driven cle-scaling' tool P, shown in Fig. 13. rllhose who are familiar with the ordinary diliiculties of 1Washing1 and cleaning' steam boilers will at once understand the convenience and importance of this simple iii'iprovement.

Keeping in mind the proportie s or dimensions above assumed, and referringl to the single, dual and triple unit boilers sliou'n in Figs. 1, 2, 5, and tu it Will be found that, as illustrated, the proi'iortiona'e grate area of the single unit boiler is tiventjpeiglit square feet; of the dual unit boiler thirty six square feet; and of the triple unit boiler fifty square feet. l have utilized these proportions to further exemplify the ease with which the capacity may be ensured by usingl a grate area of any desired size and also to show honT a boiler of any reasonably higrh efliciency (boiler and furnace efficiency) may be secured by multiplying the numbeiI of units While lessening the proportionate grate area; and yet always securing required capacities in boilers of comparatively small size, Weight and cost.

Further referring to the assembly views. it will be noted that the boiler units are suspended Within ytheir settings, being' supported at the ends of the upper drums. Not only does this facilitate erection, but What Vis more important, the Whole lower part of the boiler unit is permitted entire freedom of expansion and contraction in all directions; and by reason of this freedom and the manner in Which the bottom drum is connected to the upper drum by the parts` C and D, and CX and DX, the effects of expansion and contraction are so minimized and distributed as to obviate possibility ot rupture in any of the parts or connections.

Gbyiously, this boiler is safe and durable; for, as indicated, the drums are of comparatively small diameter; the metal sheets composing the drums and the Water-walls, though actually thin, are relatively heavy; the `e'll'fects of expansion and contraction are nullilied; ample feed Water capacity or terre porary storage is provided in the bottom drum, likewise ample space for mud in the coolest part of the boiler; complete provi-sion is made for the free disengagement of steam rising into the upper drum, and provisions besace?" are made for keeping; the boiler clean. and free from scale; each of which points has an important bearing upon the safety and durability of the boiler.

l have herein referred to the water lef@r or Wall, C, as a thermic Siphon. lt acts as such, for it draws water from the lower part of the boiler' and delivers steam and Water to the upper part thereof. .'\side from the other parts of the boiler, it closely resembles the device from which it takes its names, to-u'it; the Nicholson tlzermic sipbon as used in locomotive boiler tireboxes.

A stated before, the complete unit, by preference, is al vays suspended in its setting. als the best means to that end, l employ tivo saddle beams or cradles, il and 5, at the ends of the top drum and .support these by columns (l. These columns are preferably footed in concrete below the floor line of the boiler roon'l, as indicated by dotted lines. For a single unit, each beam contains a single saddle or notch. For a` plurality of units, each beam contains as many saddles as there are units (see Fie. 10). l: eavier beams and columns are used for the v-ider settings. The spacing between the saddles in such beams is determined by the dimensions of the grate and lire chamber to be used. Ordini'irily, the spacing between centers exceeds the drum diameter by several inches, leaving; a reasonably Wide crack to be closed by protcctilu;` lcy brick, .7. is to be noted that the described separation of the units from one another and from the side Walls of the setting, is always such that a Workman may enter the spaces between the Water Walls, as may be required.

As best shown in Fig. l. the .saddle beams, l and 5, ineferably are Zshaped in crosssection, and each presents a Wide seat, which receives the curved bearing" strip, 8, conforming to the drum. The top of each strip, 8, contains a groove that accommodates the heads of the rivets belonging" to the drum head. Thus the rivet heads serve to lock the bearing,T strips to respective ends of the drum; and the strips form slide bearings on the saddles and at the same time tightly close the c acls between the saddles and the drum. By preference the bearing strip at the rear end of the boiler is fastened to the saddle beam, whereas the bear-incr strip at the forward end o'l the drum is 'tree to slide in the cradle of the beam. il. and to thus accommodate the longitudinal expansion and contraction of the boiler unit. For sake of stability, cach pair of cross braces is braced and tied together by tivo rods or bars, tl, preferably positioned below the center of the top drum. ln this manner a simple and complete metal support or slingT is first provided for the unit or units and thereafter the setting; is completed by the addition of the side and end Walls, 10. lt

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proper lire in the tire-chamber.

is not necessary to burden these walls by `These slabs rest upon the tops otrespective side walls, and` at their upper ends lean against the adjacent boiler drum, being pitched at an angle of substantially iortyive degreeahin which position they are firm andstable. The bars, 9, are removed at the time the brick are put in place or removed. The remo-val thereof gives access to the tubes Within the gas passages of the setting. There is also a back door, l2, for that purpose. Upon the completion of the roof, the entire top of the boiler is covered with a `layer of suitableinsulating material.

As indicated, the lire chambers, l, may andshouldcontain suitably positioned iire arches orbai'lles, F', for the proper elonga- At this point it is well to understand that my boilers are primarily intended tor use with high volatile fuels, the best results being gained when the iirebox isvirtually filled with flames Eromthe lire.` Under such conditions the water `walls are veryueiective as absorbers of heat,as well as ideal water circulating and steam disengaging devices.

Thepractical use and operation of the boiler will be obvious to all those skilled in `the art. Its structural advantages have al* ready been described and referred to, but its operation and some vfurther advantages may be properly summarized at this point. For this purpose the boiler is assumed to be in operation, containing a proper level of water constantly added to through the feed water supply pipe, with steam at `given pressure dischargingr from the outlet, H, and with a The high temperature flames impart their heat to the directly opposed surfaces of the water walls C and to the underside of the top drum or drums, A. This immediate transference of radiant` heat is of prime importance. siphon being subjected `to high temperature on both sides and throughout `large areas,

`the water therein is caused to flow forward and upward ina very rapid and vigorous manner. Thesteam liberated on the inner surfacesof the iire sheets is therefore instantly swept from the sheets and, as will be apparent, all steam bubbles liberated within the siphon Irise freely and directly into the The enters from the drum, B, and. because of this and the restriction ol the thickness oii the flat columnot water in the wall, the movement of steam and water therein is limited to upward movement; and thus conflicting currents in thesiphon are avoided. The small volume et' water contained in the boiler' ensures the quick steamingl of the water and an immediate response of the boiler to every demand ior steam. In this connection it should be noted that `the amply long and very large outlet of the Siphon into t-he upper drum resuits in the entirely free liberation and distribution of steam in the `larger surfaced body ofwater in the upper drum and even in case of a sudden and abnormal steam demand there can be no localization oi steam Vflow into or within the upper drum and in consequence the steam therein is not primed and there is litt-le, it any, tendency toward a geyser-lile action of water in the direction ot the steam outlet. The steam entering the top drum from the siphon finds ample surface therein for its free and quiet disengagement, assuring a constant supply ot dry steam and only the hot water hows toward the rear end of' the drum. All water discharged and evaporated within the hollow wall C is, ot course, replaced by water flowing into it from the lower drum, B, and simultaneously, and in a positive manner, the water from the upper drum is drawn, or falls downward through the many tubes, D, and into the lower drum. `'lthe movement of the water in the return tubes is slower by reason of the greater aggregate area ot the tubes, as compared with the neck oit the siphon, `and does not militate against the ready upward escape of the steam ,generated in the tubes by the heat to which the tubes are subjected in the gas passage 3. By reason ot the fact that the wall C takes water from the upper part of the bottom drum, the hot water descendinp` through the return tubes and ba'liied by the plate N, tends to move directly toward the siphon intake and leaves the cold feed water and the mud in the bottom thereof in amore or less quiescent state. The cold tteed water thcre'lor, reaches the siphou only aiiter its temperature has been considerably raised. rllhe lower drum ttor these reasons is valuable as a settling chamber or mud drum, serving as a mud trap which retains the greater part ct the solids and prevents the passage thereof into `the siphon and upper parts ofthe boiler. By occasionally blowing out the lower drum (which is done by opening the blow-oil valve) the entire system can be lrept clean, and in consequence of this cleanliness and the absence of any surface or pocket wherein steam can collect, the boiler may be operated efficiently at -overloads and over long periods. lWhenever itis necessary to obtain access tothe interior oit' the boiler, as tor purposes oit inspecting or washing it, the

iis Y including its return tubes.

man-holes may be opened and at such times every part of the interior of the boiler becomes accessible. As explained, it is possible to Wash and descale every part of the boiler The specially important factor is that the most rapid, vigorous 'and unrestrained circulation takes place in that part `or parts ot the boiler subjected to the most intense heat, to-wit, in the water wall or Siphon, with the result that those parts are constantly maintained in the best possible working order.

Though a boiler of great capacity may be required, following the described system it will be composed oit a number of unit boilers each characterized by a drum of relatively small diameter. An important. in cident of the construction is that these small drums may be made of relatively thin sheets and yet be capable of withstanding high pressures. Further, such sheets can be handled, formed and shaped much more quickly, with less skill and more cheaply than the heavy plates ordinarily used in boiler construction. Again, the thin sheets more readily transmit heat, with aconsequent proportional increase in eliicieney.

As will be apparent, my invention is adapted to all ordinary uses of boilers in stationary. marine and portable service.

The objects and purposes outlined in the opening ot the specilication are attainable by the construction and arrangement herein shown and described, but inasmuch as this disclosure will suggest to others modied constructions whereby the substantial objects and purposes of my invention may be attained, l do not wish to be limited to the construction herein shown and described, except to the extent that the invention is defined in the appended claims.

Having thus vdescribed my invention, I

Y claim as new and desire to secure by Letters 1. A boiler unit comprising a top drum, in combination with a. bottom drum, many return ducts connecting the said drums, a substantially and operatively triangular water wall occupying vert-ical planes parallel with the airis of said top drum communieating directly with both drums and constitutine4 an uptlow passage of increasing size from bottom to top, a tire-chamber containingf said wall, and a gas passage containing said bottom drum and said return tlow ducts.

Q. A boiler unit comprising,- a long` top drum, in combination with a short bottom drum beneath the rear part of the top drum and in substantially parallel relation thereto, a plurality of vertical return tubes connecting,T said drums, and a substantially and operatively triangular Water wall which preteatros? sents its apex in communication with the forward part ot said bottom drum and its inverted base in con'nnunication with the for tard part. of said top drum.

3. A boiler unit comprising, in combination, substantially parallel top and bottom drums, the lower drum beine` ol approximately hall the length of the upper drum. a thcrmic siphon extending upward Yfrom the Vfront end of the lower drum and entering the bottom ot the upper drum. a group ot return tubes rising from the lop ot the bottom drum and entering' the bottom oi' the upper drum, the upper drum having a steam outlet. said bottom drum having.; a blow-oll connection, and the ends ot said drums containing' access openings.

4. A steam boiler comprising;- a bank ot water tubes and upper and lower drums or receivers that are carried by said tubes. in combination with a water circulating:T and steaming wall of inverted substantially and operatively triangular shape. which al the top opens into the bottom ol said upper receiver and which at its bottom rear corner :torms an intake neck in comnumication with said lower receiver. i

5. A steam boiler comprisingy a bank of *ater tubes and upper and lower drums or receivers, in combination with a water circulating,` and steaniing wall or inverted substantially and operatively triammlar shape. which at the top opens into said upper receiver and at its bottom rear corner 'forms an intake neck in communication with said lower drum and said bottom presenting an upper forward corner, below said upper drum.

6. The herein described water circulatingT and steaming` all which has llat spaced apart and staybolted sides and is ot inverted substantialhY and operatively triangular shape, open at the top and having an upwardly and Jforwardly slantine bottom which at its front, bottom portion has a blow-oil1 neck and at its lower back end has an intake neck.

T. A boiler unit comprising a tbermie phon member in combination with rererscly positioned tube sheets and a plurality ot tubes connectingl them, a top sheet. which with the top oiE said Siphon member and one ot said tube sheets completes the body ot the upper drum, a bottom sheet which with the other tube sheet completes the body of the bottom drum, heads closing' the ends of said drums and the front head of the bottom drum containing' the intake portion ot said siphon member.

ln testimony whereof, l have hereunto set my hand this 8th day of September, 1.921.

CHARLES GILBERT l-LCWLEY'.

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